UTICA BOILERS SW3 Installation, Operation & Maintenance Manual Download

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OIL FIRED DIRECT EXHAUST

CAST IRON BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

P/N# 27515401, Rev. A [03/2011]

An ISO 9001-2008 Certified Company

Utica Boilers

2210 Dwyer Avenue, Utica NY 13504-4729

Phone: (315) 797-1310 • Fax: (866) 432-7329

e-mail: [email protected]
web site: www.ecrinternational.com

Summary of Contents for SW3

Page 1: ...LATION OPERATION MAINTENANCE MANUAL P N 27515401 Rev A 03 2011 An ISO 9001 2008 Certified Company Utica Boilers 2210 Dwyer Avenue Utica NY 13504 4729 Phone 315 797 1310 Fax 866 432 7329 e mail info ecrinternational com web site www ecrinternational com ...

Page 2: ... Utilizing 3 4 Tapping 10 Oil Tank And Piping 11 Electrical Wiring 12 Thermostat Installation 13 Normal Sequence Of Operation 14 Operating Instructions 14 Instructions To Obtain Proper Operation Of The Boiler Burner Unit 15 Preventive Maintenance 16 Instructions For Opening And Closing Burner Swing Door 16 Service Check List 17 Sw Series Replacement Parts 18 Dimensions 26 Read All Instructions Bef...

Page 3: ...ppliance with improper methods or materials may result in serious injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided may result in minor or moderate injury WARNING Ind...

Page 4: ...ment of another appliance such as water heater Installation on Combustible Floors Boiler shall not be installed directly on carpeting tile or other combustible material other than wood flooring Boiler must not be installed on carpeting or vinyl flooring Installation WARNING Improper installation adjustment alteration service or maintenance could result in personal injury or loss of life Minimum cl...

Page 5: ...ng NOTICE Circulators in following illustrations are mounted on system supply side mounting on system return side is also acceptable practice Figure 1 Typical Installation Using Circulators Figure 2 Typical Installation Using Zone Valves ...

Page 6: ...ler water temperature to fit system or condition of installation This method of piping is not typically required for baseboard heating systems CONNECTING SUPPLY AND RETURN PIPING Method used to protect systems using radiant panels and material they are encased in from high temperature supply water from boiler See Figure 3 Method used to protect boilers from condensate forming due to low temperatur...

Page 7: ...7 CONNECTING SUPPLY AND RETURN PIPING Figure 4 Figure 5 ...

Page 8: ...ycle open valves A and B close valves 9 C and D During heating cooling cycle open valves C and D close 10 valves A and B Maintain minimum clearance of one inch to hot A water pipes In air handling units where they may be exposed to refrigerated air circulation boiler piping system MUST be supplied with flow control valves or other automatic means to prevent gravity circulation of boiler water duri...

Page 9: ...d on the outlet of the domestic coil Installation must comply with the valve manufacture s recommendations and instructions Do not remove the bolts or aquastat at the time of installation Pipe in accordance with the installation manual Due to varying water conditions an adjustable flow restrictor must be installed in the cold water inlet of this coil Figure 7 Recommended Piping For Boilers Equippe...

Page 10: ...10 Options Utilizing 3 4 Tapping Figure 8 Optional Location For Air Vent Figure 9 Optional Location For Expansion Tank Non Diaphragm Type ...

Page 11: ...mmended Compression fittings on suction line often allow air to be drawn into fuel pump making it difficult to maintain oil pressure at nozzle Oil Tank And Piping Do not run overhead fuel lines from tank to oil burner Fuel pump connections and by pass should be made according to instructions attached to fuel pump If tank is more than 20 from the boiler a two stage fuel unit should be installed in ...

Page 12: ...NE VOLTAGE BY FACTORY LOW VOLTAGE BY FACTORY LINE VOLTAGE BY INSTALLER LOW VOLTAGE BY INSTALLER Not all components listed are used in all control systems Component Coding TH 1 Thermostat millivolt TH 2 Thermostat 24 Volt TH 3 Thermostat Line Voltage TR 1 Transformer 120V 24V 40VA TR 2 Transformer 120V 24V 50VA LGV 24 Volt Gas Valve PS Pressure Switch MR PS Manual Reset Pressure Sw Control Terminal...

Page 13: ...ixtures D Television sets E A fireplace or chimney F Thermostat Installation ELECTRICAL WIRING Check thermostat operation by raising and lowering 4 thermostat as required to start and stop burner Instructions for final adjustment of thermostat 5 are packaged with thermostat adjusting heating anticipator calibration ect Figure 13 Wiring Diagram For Oil Fired Boilers With A Circulator Zoned System A...

Page 14: ...urner motor starts prepurge and approximately 15 seconds after solenoid valve opens and ignition system is activated ignition will begin In event boiler water temperature exceeds high limit setting on boiler mounted aquastat Power will be interrupted between aquastat and ignition system Burner motor will continue to run in post purge mode for approximately 2 min or until water temperature drops be...

Page 15: ...mance High limit control A remove cover and note temperature setting See figure 15 on page 15 With burner operating decrease this setting to minimum point When boiler water temperature exceeds this set point high limit switch will open shutting off power to oil burner and starting post purge cycle for approximately 2 minutes Return setting to desired high limit point Burner should restart Primary ...

Page 16: ...es for carbon or cracks in insulators Burners should be adjusted to produce conditions shown in Start up and Adjustment of Oil Burner procedure Instructions for Closing Burner Swing Door Swing burner and door to right until insulation is 1 slightly compressed and stud is exposed Attach nut to stud and tighten it until built in stop 2 contacts mounting door Replace oil line to burner 3 Preventive M...

Page 17: ... Nozzle Size Angle Type Pump Pressure Vacuum Line Voltage Motor Amps Smoke Test Draft Over fire In Flue CO2 or O2 Flue Gas Temperature Proper Light Off Hot Cold Controls and Safety Devices Measure with Instruments and Record results on chart provided below Pump Flue Date Nozzle Pressure Smoke Draft CO2 or O2 Temperature Size Angle Type PSI NO O F INF o F Service Check List ...

Page 18: ...ULATION BLANKET 1 7 N A N A N A 8 HW 025 01 TIE ROD 1 2X12 1 2 3 SEC 1 HW 025 01 TIE ROD 1 2X12 1 2 4 SEC 1 9 100 1 5 01 22 PUSH NIPPLE 3 Section 2 4 Section 3 5 Section 4 10 MS 006 00 ROPE MED DENSITY 3 Section 13 4 Section 19 5 5 Section 26 11 HW 008 03 WASHER 1 2 ID FLAT 3 12 HW 003 05 NUT 1 2 13 HEX HEAD 3 FULLY ASSEMBLED HEAT EXCHANGERS PART DESCRIPTION 10023701 3 SECT WITH TANKLESS COIL 1002...

Page 19: ...COIL 1 AQ 010 00 CONTROL L8124A FOR BOILERS WITH A TANKLESS COIL 1 6 AQ 020 01 WELL 1 7 28512201 HARNESS AQUASTAT 1 8 28512301 HARNESS BURNER BECKETT 1 1263011 HARNESS BURNER RIELLO 1 9 5612001 TANKLESS COIL KIT P3 FOR 3 SECTION BOILERS 1 5612002 TANKLESS COIL KIT T4 FOR 4 5 SECTION BOILERS 1 10 27511401 TANKLESS COVER KIT 1 11 PF 002 04 PIPE FIT ELBOW 3 4 NPT 1 12 PF 005 11 PIPE FIT NPL 3 4 X 4 N...

Page 20: ...RVATION DOOR 1 4 25511101 OBSERVATION DOOR GASKET 1 5 HW06801 1 4X1 3 4 DRIVE LOCK PIN 2 6 10011501 SWING DOOR 1 7 HW06701 5 16X18X2 3 8 STUD 1 8 2553301 INSULATION SWING DOOR FOR BOILERS WITH RIELLO BURNERS ONLY 1 2553303 INSULATION SWING DOOR FOR BOILERS WITH BECKET BURNERS ONLY 1 9 10011301 MOUNTING DOOR 1 Figure 18 Swing Door And Mounting Door Components ...

Page 21: ...SIDE PANEL 4 SECTION 2 21521804 SIDE PANEL 5 SECTION 2 2 21522401 TOP FRONT PANEL C O 1 21522402 TOP FRONT PANEL TANKLESSS COIL SHOWN 1 3 21521901 LOWER COWL 1 4 21521501 REAR PANEL 1 5 215 1 3 02 TOP PANEL 3 SECTION 1 215 1 3 03 TOP PANEL 4 SECTION 1 215 1 3 04 TOP PANEL 5 SECTION 1 Figure 19 Jackets ...

Page 22: ...1 24521302 FLUE COLLECTOR ASSY 4 SECT 1 24521303 FLUE COLLECTOR ASSY 5 SECT 1 3 HW06701 STUD 5 16 18 X 2 3 8 4 4 2252501 SUPPORT JACKET BRACKET 1 5 HW06901 NUT 5 16 18 WISLOCK 8 6 HW07001 STUD 5 16 18 X 1 3 8 3 7 HW 016 02 DRAIN LONG 1 8 PF 004 04 PIPE FIT BUSHING 1 1 4 X 3 4 1 9 HW06401 NUT ACORN 1 2 13 UNC YELLOW 2 Figure 20 Hardware ...

Page 23: ...PART DESCRIPTION QTY 1 1580004 TERMINATION 4 FLEX L CFTSW4 UT 1 2 1580005 TERM KIT 4 FLEX L CFK104 UT INCLUDES A B C A TERMINAL ADAPTER CFAT44 1 B 10 x 4 VENT KIT CFV104 6 1 C APPLIANCE ADAPTER CFAA44P 1 Figure 21 Termination Kit Assembly ...

Page 24: ...1 1320024 NOZZLE 1 10 60B SW5 RIELLO 1 6 CALL BURNER OIL 40BF3 SW3 RIELLO 1 CALL BURNER OIL 40BF5 SW4 RIELLO 1 CALL BURNER OIL 40BF5 SW5 RIELLO 1 BECKETT AFII BURNER PARTS 1 RP03801 BLAST TUBE AF2 2 RP03901 FUEL PUMP AF2 DANFOSS 3 RP04001 7 DRAWER ASSY AF2 4 RP04101 OIL BRN TRANSFORMER AF2 5 RP04201 OIL BRN MOTOR AF2 6 RP03701 FUEL PUMP 7 RP04401 SOLENOID VALVE COMB RIELLO BURNER PARTS 1 30A064701...

Page 25: ...ed Boiler Flush Jacket Oil Burner Target Wall Liner Circulator 1 1 4 ASME Relief Valve Theralitimeter Gauge Drain Cock Wiring Harness Burner Electrical Disconnect Plastic Cover Supply Tapping 2 Return Tapping 1 1 4 High Limit and Circulator Control Primary Control For Tankless Heater Units add Tanlkess Hot Water Coil Flow Restrictor and Triple Aquastat Relay TANKLESS WATER HEATER CAPACITIES BOILER...

Page 26: ...il heating value of 140 000 Btu gal and with 13 CO2 3 Net ratings based on 170 0 F temperature in radiators and include 15 allowance for normal piping and pickup load Consult manufacturers for unusual piping and pick up requirements All ratings subject to verification 4 120 Volts 15 Amps 60 Hz required to operate this boiler 5 The MEA number for the SFH W series is 182 86E 6 The MEA number for the...

Page 27: ...27 SW series oil fired direct exhaust cast iron boiler ...

Page 28: ...SW OIL FIRED DIRECT EXHAUST CAST IRON BOILER ...

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